Cell stack device, module, and module housing device

ABSTRACT

A cell stack device may include a cell stack comprising a plurality of cells, a manifold configured to supply a reaction gas to the plurality of cells, and a reaction gas supply pipe connected to the manifold. The manifold may include an insertion portion configured to connect the reaction gas supply pipe to the manifold and a first joining portion configured to join the insertion portion and the reaction gas supply pipe. A module may include the cell stack device contained in a housing container. A module housing device may include the module, an auxiliary device configured to operate the module, and an external casing configured to contain the module and the auxiliary device therein.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/345,280 filed on Apr. 26, 2019, which is a national stage entryaccording to 35 U.S.C. § 371 of PCT Application No. PCT/JP2017/038732filed on Oct. 26, 2017, which claims priority to Japanese ApplicationNo. 2016-210735 filed on Oct. 27, 2016, and Japanese Application No.2017-057653 filed on Mar. 23, 2017, which are entirely incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure relates to a cell stack device, a module, and amodule housing device.

BACKGROUND ART

In recent years, cell stack devices have been proposed, asnext-generation energy sources, in which a plurality of fuel cells, eachof which is a type of cell that can generate electrical power using afuel gas (hydrogen-containing gas) and air (oxygen-containing gas), arearranged in a manifold. The manifold, made of metal, may be providedwith a fuel gas supply pipe that is made of metal and configured tointroduce a gas into an interior space of the manifold. One end of thefuel gas supply pipe may be inserted into an insertion portion providedin the manifold, and the fuel gas supply pipe and the manifold arejoined together by welding or the like (see Patent Document 1: JP2014-143162 A, for example).

SUMMARY

A cell stack device according to a non-limiting aspect of the presentdisclosure may include a cell stack including a plurality of cells, eachof the plurality of cells having a columnar shape and internallyincluding a gas flow passage, the plurality of cells being verticallyarranged and electrically connected, a manifold configured to fix lowerends of the plurality of cells and supply a reaction gas into the gasflow passages of the plurality of cells; and a reaction gas supply pipeconnected to the manifold and configured to supply the reaction gas tothe manifold. The manifold and the reaction gas supply pipe may be madeof metal. The manifold may include an insertion portion configured toconnect the reaction gas supply pipe, a gap between the insertionportion and the reaction gas supply pipe, and a first joining portionconfigured to seal one end of the gap as a result of joining theinsertion portion and the reaction gas supply pipe. In an arbitrarilydefined cross-section along an insertion direction of the reaction gassupply pipe, the first joining portion may have a meniscus shape. Ajoint length, in the insertion direction, between the first joiningportion and the reaction gas supply pipe may be longer than a thicknessof the reaction gas supply pipe.

A module according to a non-limiting aspect of the present disclosuremay include the cell stack device described above contained in a housingcontainer.

A module housing device according to a non-limiting aspect of thepresent disclosure may include the module described above, an auxiliarydevice configured to operate the module, and an external casingcontaining the module and the auxiliary device therein.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side view and a partial cross-sectional view illustrating anon-limiting example of a cell stack device according to the presentdisclosure.

FIG. 2 is an enlarged cross-sectional view illustrating a non-limitingexample of a section T of FIG. 1.

FIG. 3 is an enlarged cross-sectional view illustrating anothernon-limiting example of the section T of FIG. 1.

FIG. 4 is a SEM photograph of a connecting portion in FIG. 1.

FIG. 5 is an enlarged cross-sectional view illustrating a non-limitingexample of the section T of FIG. 1.

FIG. 6 is an external perspective view illustrating another non-limitingexample of the cell stack device according the present disclosure.

FIG. 7 is a plan view of the cell stack device illustrated in FIG. 6with a part thereof not illustrated.

FIG. 8 is a cross-sectional view taken along a line X-X in FIG. 7 with apart thereof illustrated in a side view.

FIG. 9 is an enlarged cross-sectional view illustrating a non-limitingexample of a section B of FIG. 8.

FIG. 10 is an enlarged cross-sectional view illustrating anothernon-limiting example of the section B of FIG. 8.

FIG. 11 is an external perspective view illustrating a non-limitingexample of a module according to the present disclosure.

FIG. 12 is a perspective view illustrating a non-limiting example of amodule housing device according to the present disclosure with a partthereof not illustrated.

DETAILED DESCRIPTION

A cell stack device, a module, and a module housing device will bedescribed using FIGS. 1 to 12.

The cell stack device illustrated in FIGS. 1 to 12 is configured by anarrangement of a plurality of fuel cells, each of which is a type ofcell, and the following description will be made using the fuel cell asa non-limiting example of the cell.

FIG. 1 is a side view illustrating a non-limiting example of the cellstack device according to the present disclosure with a part thereofillustrated as a cross-sectional view for ease of understanding. Notethat in the subsequent drawings, the same reference numerals are usedfor the same components.

A cell stack device 1 illustrated in FIG. 1 includes a cell stack 2provided with a plurality of columnar fuel cells 3. Each of the fuelcells 3 includes a gas flow passage in the interior thereof, and isconfigured by layering sequentially a fuel electrode layer that servesas an inner electrode layer, a solid electrolyte layer, and an airelectrode layer that serves as an outer electrode layer, on one flatface of an electrically conductive support body that includes a pair ofopposing flat faces and has an overall column shape and a flatcross-section. An interconnector is layered on a section of the otherflat face on which the air electrode layer is not formed. Then, the fuelcells 3 are electrically connected to each other in series byinterposing electrically conductive members between the fuel cells 3adjacent to each other. Each member of the fuel cell 3 will be describedlater. Note that, in the following description, a description will bemade using the fuel cell that includes the fuel electrode layer as theinner electrode layer and the air electrode layer as the outer electrodelayer, but the fuel cell can also be configured by the air electrodelayer as the inner electrode layer and the fuel electrode layer as theouter electrode layer.

Cell Stack Device

The cell stack device 1 illustrated in FIG. 1 is provided with a cellstack 5 that is configured by fixing the lower ends of the fuel cells 3to a manifold 4 using an insulating adhesive (not illustrated), such asa glass sealing material. In the non-limiting example illustrated inFIG. 1, the manifold 4 is a box-shaped member that includes an upperwall, a lower wall, and a plurality of side walls.

At each of end portions of the cell stack 5, an electrically conductiveend member 11 is disposed, which includes an electrically conductiveunit 12 for collecting electricity generated by the power generation inthe cell stack 5 (the fuel cells 3) and drawing the electricity to theoutside.

A reformer 6 is disposed above the cell stack 5, as a gas supply sourcefor producing a fuel gas (hereinafter sometimes simply referred to as a“gas”), which is a reaction gas supplied to the fuel cells 3. Aconfiguration can be adopted in which the cell stack device 1 includesthe reformer 6.

The reformer 6 illustrated in FIG. 1 reforms a raw fuel, such as naturalgas or kerosene, supplied via a raw fuel supply pipe 10 and produces thegas. Note that the reformer 6 can have a structure that enables steamreforming, which is an efficient reformation reaction. The reformer 6 isprovided with a vaporizing unit 7 configured to vaporize water, and areforming unit 8 in which is disposed a reforming catalyst (notillustrated) for reforming the raw fuel into the gas. Then, the gasproduced in the reformer 6 is supplied to the manifold 4 via a fuel gassupply pipe 9 that is a reaction gas supply pipe, and is then suppliedvia the manifold 4 to the gas flow passages provided inside the fuelcells 3. Note that, in a case where the fuel cell 3 that includes theair electrode layer as the inner electrode layer is used, anoxygen-containing gas supply pipe may be used as the reaction gas supplypipe.

In FIG. 1, the fuel gas supply pipe 9 and the manifold 4 are illustratedin a cross-sectional view, and the rest is illustrated in a side view.

FIG. 2 is an enlarged cross-sectional view illustrating a non-limitingexample of a section T of FIG. 1.

One end of the fuel gas supply pipe 9 is connected to the reformer 6,and the other end thereof is inserted into an insertion portion 14provided in the manifold 4 and joined with the manifold 4. The manifold4 and the fuel gas supply pipe 9 can be manufactured from a heatresistant metal such as alumina-forming stainless steel or achromia-forming stainless steel. The insertion portion 14 is a throughhole provided in the manifold 4, and although it is provided in theupper face of the manifold 4 in the non-limiting example illustrated inFIG. 2, the insertion portion 14 may be provided in either face of themanifold 4. The thickness of the fuel gas supply pipe 9 and the manifoldcan each be from 0.5 mm to 3 mm.

As illustrated in FIG. 2, a gap 14 a is provided between the insertionportion 14 of the manifold 4 and the fuel gas supply pipe 9. In thisway, the fuel gas supply pipe 9 is allowed to move more easily insidethe insertion portion 14, thereby enabling stress on a first joiningportion 17 (hereinafter referred to as a “first joining portion”)between the fuel gas supply pipe 9 and the manifold 4 to be alleviated.As a result, the fuel gas supply pipe 9 and the manifold 4 can bestrongly joined. The gap 14 a may be provided over the entirecircumference of the insertion portion 14 and the fuel gas supply pipe9, or may be provided over a part of the circumference. The gap 14 a canbe from 0.05 mm to 1.0 mm.

As illustrated in FIG. 2, the cell stack device 1 according to anon-limiting example of the present disclosure includes the firstjoining portion 17 that seals one end of the gap 14 a as a result ofjoining the insertion portion 14 and the fuel gas supply pipe 9. In anarbitrarily defined cross-section along an insertion direction of thefuel gas supply pipe 9, the first joining portion has a meniscus shape,and a joint length D1 between the first joining portion 17 and the fuelgas supply pipe 9 in the insertion direction is longer than a thicknessD2 of the fuel gas supply pipe 9.

As a result, the toughness of the first joining portion 17 between thefuel gas supply pipe 9 and the manifold 4 can be maintained at a highlevel, and cracks in the first joining portion 17 can be inhibited.Specifically, the long-term reliability of the cell stack device 1, amodule 20, and a module housing device 40 can be improved.

Note that “sealing one end of the gap” means that the one end of the gap14 a on the inner side of the manifold 4 may be sealed, or the one endof the gap 14 a on the outer side of the manifold 4 may be sealed. In acase where the one end of the gap 14 a on the inner side of the manifold4 is sealed, the first joining portion 17 is provided in the interior ofthe manifold 4. Note that both the ends of the gap 14 a may be sealed,and in this case, a surface of the first joining portion 17 exposed to ahydrogen-containing gas is referred to as a first surface S1, and asurface on the opposite side is referred to as a second surface S2.

In addition, the “first joining portion” means a region surrounded, inthe arbitrarily defined cross-section along the insertion direction ofthe fuel gas supply pipe 9, by the first surface S1, the second surfaceS2, a line connecting ends of the first surface S1 and the secondsurface S2 on the manifold 4 side and a line connecting ends of thefirst surface S1 and the second surface S2 on the fuel gas supply pipe 9side.

Further, the “meniscus shape” may be a concave meniscus shape asillustrated in FIGS. 2 and 3, or may be a convex meniscus shape.

Furthermore, the “thickness of the fuel gas supply pipe” D2 is athickness of a part of the fuel gas supply pipe having the smallestthickness. However, the thickness of a part of the first joining portion9 that is in contact with the first joining portion 17 is excluded.

Here, the second surface S2 may be formed as a part in which a structureof a crystal close to the surface is a dendritic structure, or may beformed as a part that has a different material composition from each ofthe manifold 4 and the fuel gas supply pipe 9.

Further, the joint length D1 may be shorter than double the thickness ofthe fuel gas supply pipe 9. In this way, the manifold 4 and the fuel gassupply pipe 9 is joined via the first joining portion 17 more stronglythan necessary, and the freedom of movement of the first joining portion17 is reduced; as a result, a concentration of the stress on the firstjoining portion 17 can be inhibited.

In addition, in the arbitrarily defined cross-section along theinsertion direction of the fuel gas supply pipe 9, the joint length D1in the insertion direction may be longer than a thickness D3 of themanifold 4. As a result of this, even when the manifold 4 is vibrated inthe insertion direction of the fuel gas supply pipe 9, cracks can beinhibited from occurring in the vicinity of a joint interface betweenthe first joining portion 17 and the fuel gas supply pipe 9.

Note that the “thickness of the manifold” D3 is a thickness of a parthaving the smallest thickness of the wall of the manifold 4 in which theinsertion portion 14 is provided, but the thickness of a part of themanifold 4 that is in contact with the first joining portion 17 isexcluded.

FIG. 3 is an enlarged cross-sectional view illustrating anothernon-limiting example of the section T of FIG. 1.

In the non-limiting example illustrated in FIG. 3, a length D4 of thegap 14 a in the insertion direction of the fuel gas supply pipe 9 islonger than the thickness D3 of the manifold 4. As a result of this, incomparison with a case in which the length D4 of the gap 14 a is shorterthan the thickness D3 of the manifold 4, an amount of the gas blownagainst the first surface S1 that is in contact with the gap 14 a can bereduced. Specifically, hydrogen embrittlement of the first surface S1can be inhibited.

The non-limiting example illustrated in FIG. 3 can be realized byproviding a first bent portion 14 b, which extends toward the reformer 6side along the fuel gas supply pipe 9, around a peripheral edge of theinsertion portion 14 on the outer side of the manifold 4. By includingthe first bent portion 14 b, the manifold 4 and the fuel gas supply pipe9 are more easily joined, and the fuel gas supply pipe 9 is also moreeasily inserted into the insertion portion 14. Note that a height H1 ofthe first bent portion 14 b can be from 2 mm to 5 mm, for example.

In addition, an annular member, which extends toward the reformer 6 sidealong the fuel gas supply pipe 9, may separately be provided around anouter periphery of the insertion portion 14. As another non-limitingexample, the bent portion or the annular member may be provided aroundthe peripheral edge of the insertion portion on the inner side of themanifold.

In the non-limiting example illustrated in FIG. 3, the first joiningportion 17 is provided on a leading end of the first bent portion 14 b,and the first bent portion 14 b and the fuel gas supply pipe 9 arejoined via the first joining portion 17. Meanwhile, as anothernon-limiting example, the first joining portion 17 may be provided onthe first bent portion 14 b on the manifold 4 side.

FIG. 4 is a scanning electron microscope (SEM) photograph of across-section near the surface of the first joining portion 17. Notethat, FIG. 4 illustrates a state of a result obtained by measuringcrystal areas to be described below.

As illustrated in FIG. 4, in the arbitrarily defined cross-section alongthe insertion direction of the fuel gas supply pipe 9, an averagecrystal area of the first joining portion 17 can be 10000 μm² or lesswith respect to crystals present in a region (hereinafter referred to asan “analysis region”) that is surrounded by a portion of an analysissurface A having a length of 500 μm in the first joining portion 17, twovertical lines B1 and B2 each having a length of 500 μm and havingrespective start points a1 and a2 at both ends of the analysis surfaceA, and a line C joining two end points c1 and c2 of the vertical lines.In this way, the strength of the first joining portion 17 can beincreased. Further, in order to further increase the strength of thefirst joining portion 17, the average crystal area may be 4000 μm² orless. Further, of the crystals in the analysis region of the firstjoining portion 17, the crystal area of all of the crystals (of eachindividual crystal), may be 40000 μm² or less. Note that “ . . .crystals present in a region that is surrounded by” does not only referto the crystals entirely included in the analysis region, but alsorefers to the crystals that are partially included in the analysisregion.

Further, as illustrated in FIG. 4, in the region of the first joiningportion 17, the average crystal area of the crystals positioned on theanalysis surface A, of the first joining portion 17, having the lengthof 500 μm can be 5000 μm² or less. In this way, since the strength canbe increased in the vicinity of the second surface in which crackseasily occur, the strength of the first joining portion 17 can befurther increased.

A method will be described for identifying the crystal area of thecrystals in a cross-section of the first joining portion 17. Firstly,the scanning electron microscope is used to obtain a channeling contrastimage in a cross section of the first joining portion 17 that includesthe second surface. Next, the crystals appearing in the obtainedchanneling contrast image are identified. Lastly, of the identifiedcrystals, the crystal areas of the crystals surrounded by theabove-described analysis region are identified using an image analysismethod or the like.

A non-limiting example of a method for manufacturing the above-describedmanifold 4 according to the present disclosure will be described next.

The first joining portion 17 that joins the fuel gas supply pipe 9 andthe manifold 4 can be provided by joining the manifold 4 and the fuelgas supply pipe 9 using a metallurgical joining method. Themetallurgical joining methods are methods to perform joining throughfusion welding, pressure welding, or soldering. Non-limiting examples ofthe fusion welding include laser welding, plasma arc welding, inert gasarc welding, MAG welding, gas welding, or the like. Further,non-limiting examples of the pressure welding include ultrasonicwelding, friction welding, explosive welding, or the like.

Adjustment of the joint length D1 between the first joining portion 17and the fuel gas supply pipe 9, in the arbitrarily defined cross-sectionof the first joining portion 17 along the insertion direction of thefuel gas supply pipe 9, and adjustment of the crystal area of thecrystals of the second surface of the first joining portion 17 can berealized by adjusting, as appropriate, various conditions of the joiningmethod of the metallurgical joining methods. For example, in a casewhere the first joining portion 17 is provided by welding, theadjustments can be realized by adjusting an irradiation angle and anirradiation output of a heat source.

FIG. 5 is an enlarged cross-sectional view illustrating a non-limitingexample of the section T of FIG. 1. In the present non-limiting example,an angle θ1 of the first joining portion 17 can be 30° or less. In thisway, even if the fuel gas supply pipe 9 is deformed or moves, stressacting on the first joining portion 17, particularly stress acting on afirst leading end portion 17 b, can be alleviated, and the reliabilityof the joint between the fuel gas supply pipe 9 and the manifold 4 canbe improved.

Here, as illustrated in FIG. 5, in the arbitrarily defined cross-sectionin the insertion direction of the fuel gas supply pipe 9, the angle θ1is an angle formed between a vertical line drawn from the first leadingend portion 17 b of the first joining portion 17 toward the manifold 4,and a first straight line L1 joining a first point 17 c and the firstleading end portion 17 b, the first point 17 c being in a first contourline S3 of the first joining portion 17 and positioned at a height thatis half of a height from a first bottom portion 17 a to the firstleading end portion 17 b of the first joining portion 17.

Further, in the course of further suppressing damage and the like to thefirst joining portion 17, a shape can be adopted in which the angle θ1is 20° or less.

Further, the first joining portion 17 can be a concave meniscus shape,or a linear shape. In this way, it is possible to inhibit the stressacting on the first joining portion 17 from concentrating on a singlepoint, and the stress acting on the first joining portion 17 can bealleviated.

FIG. 6 is an external perspective view illustrating another non-limitingexample of the cell stack device according to the present disclosure,and FIG. 7 is a plan view of the cell stack device illustrated in FIG. 6with a part thereof not illustrated. Further, FIG. 8 is across-sectional view of the fuel gas supply pipe 9, the manifold 4, anda straightening plate 16 taken along a line X-X in FIG. 7, and othermembers are illustrated in a side view.

The manifold 4 of a cell stack device 111 illustrated in FIG. 6 to FIG.8 includes a main body portion 4 a including a space that iscommunicated with the gas flow passages, and a flange portion 4 b thatprotrudes from the main body portion 4 a. The gas is supplied to thefuel cells 3 via the space in the main body portion 4 a. The other endof the fuel gas supply pipe 9 is joined to the manifold 4 by beinginserted from the side of a first face n1 into a first through hole 14d, which is the insertion portion 14, configured to penetrate throughthe flange portion 4 b. Further, the other end of the fuel gas supplypipe 9 is joined to the manifold 4 by being inserted from the side of asecond face n2 into the second through hole 14 e, which is the insertionportion 14, configured to penetrate through the main body portion 4 a.Then, the manifold 4 includes the straightening plate 16 that isseparated from the other end of the fuel gas supply pipe 9 and coversthe other end. In other words, in order to improve a flow distributionratio, the straightening plate 16 is provided perpendicularly to aflow-out direction of gas flowing out from the second through hole 14 e.Further, the straightening plate 16 includes an opening portion. Theopening portion may be provided such that the gas flows toward the fuelcell 3 at the end of the cell stack 5 that is separated from thestraightening plate 16. Note that, of the first face n1 and the secondface n2, in the manifold 4, the surface on the side on which the cellstack 5 is joined and mounted is the first face n1, and the surface onthe opposite side to the first face n1 is the second face n2.

Note that, since the joining (the first joining portion) of the firstthrough hole 14 d and the fuel gas supply pipe 9 can adopt theabove-described configuration illustrated in FIG. 2 to FIG. 5, anexplanation is omitted, and hereinafter, the joining of the fuel gassupply pipe 9 to the second through hole 14 e will be described.

FIG. 9 is an enlarged cross-sectional view illustrating a non-limitingexample of a section B of FIG. 8. In the present non-limiting example,the other end of the fuel gas supply pipe 9 and the manifold 4 arejoined via a second joining portion 18. Here, in the presentnon-limiting example, an angle θ2 of the second joining portion 18 canbe 30° or less. In this way, even if the fuel gas supply pipe 9 isdeformed or moves, stress acting on the second joining portion 18,particularly stress acting on a second leading end portion 18 b, can bealleviated, and the reliability of the joint between the fuel gas supplypipe 9 and the manifold 4 can be improved.

Here, in the arbitrarily defined cross-section in the insertiondirection of the fuel gas supply pipe 9, the angle θ2 is an angle formedbetween a vertical line drawn from the second leading end portion 18 bof the second joining portion 18 toward the manifold 4, and a secondstraight line L2 joining a second point 18 c and the second leading endportion 18 b, the second point 18 c being in a second contour line S4 ofthe second joining portion 18 and positioned at a height that is half ofa height from a second bottom portion 18 a to the second leading endportion 18 b of the second joining portion 18.

Further, in the course of further suppressing damage and the like to thesecond joining portion 18, a shape can be adopted in which the angle θ2is 20° or less.

As illustrated in FIG. 9, the second joining portion 18 can be theconcave meniscus shape, or the linear shape. In this way, it is possibleto inhibit the stress acting on the second joining portion 18 fromconcentrating on a single point, and the stress acting on the secondjoining portion 18 can be alleviated.

FIG. 10 is an enlarged cross-sectional view illustrating anothernon-limiting example of the section B of FIG. 8.

In a non-limiting example illustrated in FIG. 10, a second bent portion14 c is provided which extends toward the reformer 6 along the fuel gassupply pipe 9, around an outer periphery of the second through hole 14 ein the manifold 4, and an end portion of the second bent portion 14 cand the fuel gas supply pipe 9 are joined via the second joining portion18. In this way, since the manifold 4 includes the second bent portion14 c, the joining of the manifold 4 and the fuel gas supply pipe 9becomes easier, and moreover, the fuel gas supply pipe 9 is more easilyinserted into the second through hole 14 e. Note that a height H2 of thesecond bent portion 14 c can be from 2 mm to 5 mm, for example.

A non-limiting example of a method for manufacturing the above-describedmanifold 4 according to the present disclosure will be described. Asillustrated in FIG. 8, for example, manufacturing methods will bedescribed below in detail of the manifold 4 in which the first throughhole 14 d is formed in the flange portion 4 b, and the second throughhole 14 e is formed in the main body portion 4 a.

The first through hole 14 d is formed by penetrating the flange portion4 b through a processing method, such as a punching process. Similarly,the second through hole 14 e is formed by penetrating the main bodyportion 4 a through a processing method, such as the punching process.

The first joining portion 17 and the second joining portion 18 to whichthe fuel gas supply pipe 9 and the manifold 4 are joined can be providedby joining an outer surface of the manifold 4 and the fuel gas supplypipe 9 using a metallurgical joining method. The metallurgical joiningmethods are the methods to perform joining through the fusion welding,the pressure welding, or the soldering. Non-limiting examples of thefusion welding include the laser welding, the plasma arc welding, theinert gas arc welding, the MAG welding, the gas welding, or the like.Further, non-limiting examples of the pressure welding include theultrasonic welding, the friction welding, the explosive welding, or thelike.

Further, in the manifold 4, in order to provide the first bent portion14 b and the second bent portion 14 c formed integrally with the outerperipheries of a first through hole 14 d and the second through hole 14e, respectively, the first bent portion 14 b and the second bent portion14 c can be manufactured by a processing method such as the pressingprocess using dies having the shapes of the first bent portion 14 b andthe second bent portion 14 c. Further, in a case where the first bentportion 14 b and the second bent portion 14 c are provided separatelyfrom the outer peripheries of the first through hole 14 d and the secondthrough hole 14 e, respectively, members having the shapes of the firstbent portion 14 b and the second bent portion 14 c may be prepared, andthe respective members may be joined to the outer peripheries of thefirst through hole 14 d and the second through hole 14 e using theabove-described metallurgical joining method.

Cell

A well-known general material may be used for the fuel electrode layer.For example, the fuel electrode layer can be formed of a porouselectrically conductive ceramic, such as ZrO₂ solid solution with a rareearth element oxide (referred to as a stabilized zirconia that alsoincludes partially stabilized zirconia), and at least one of Ni and NiO.

The solid electrolyte layer functions as an electrolyte that allowselectron transfer between the electrodes, and has a gas blockingproperty that prevents leaks of the fuel gas and the oxygen-containinggas. The solid electrolyte layer is formed of ZrO₂ solid solutioncontaining 3 to 15 mol % of the rare earth element oxide. Note that thesolid electrolyte layer may be formed from another material as long asthat material exhibits the above-described properties.

The material for an oxygen electrode layer is not particularly limited,and any well-known general material may be used. For example, the oxygenelectrode layer can be formed of an electrically conductive ceramic madefrom a so-called ABO₃ perovskite oxide. The oxygen electrode layer isgas permeable, and the open porosity thereof is in a range of 20% ormore, and particularly in a range from 30 to 50%.

The interconnector can be formed from an electrically conductiveceramic, but since the interconnector comes contact with the fuel gas(the hydrogen-containing gas) and the oxygen-containing gas (air or thelike), a lanthanum chromite perovskite oxide (LaCrO₃ based oxide) thatis reduction resistant and oxidation resistant can be used. In order toprevent leaks of the fuel gas flowing through gas flow passages formedby the support body and the oxygen-containing gas flowing on the outerside of the fuel cells 3, the interconnector is dense and has a relativedensity of 93% or greater, and particularly 95% or greater.

The support body is gas permeable to allow the fuel gas to permeatetherethrough and arrive at the fuel electrode layer, and further, iselectrically conductive to allow current collection via theinterconnector. Thus, a material that satisfies these requirements, suchas an electrically conductive ceramic or cermet can be used as thesupport body.

Moreover, in each of the fuel cells 3 illustrated in FIG. 1, thecolumn-shaped support body is an elongated plate that extends in theerecting direction of the fuel cells 3, and has a shape of a hollow flatplate that includes a pair of opposing flat surfaces and twosemicircular side surfaces. Then, lower end portions of the fuel cells 3and a lower end portion of the above-described electrically conductivemember are fixed to the manifold 4 that supplies the fuel gas to thefuel cells 3, by the insulating adhesive, such as the glass sealingmaterial, and the gas flow passages provided in the support bodycommunicate with a fuel gas chamber inside the manifold 4.

During the manufacture of the fuel cells 3, in a case where the supportbody is manufactured by simultaneously sintering with the fuel electrodelayer or the solid electrolyte layer, the support body can be made froman iron group metal, such as Ni, and a specific rare earth oxide, suchas Y₂O₃. In addition, to ensure the fuel gas permeability, the supportbody has an open porosity of 20% or more, and particularly in a rangefrom 25 to 50%. The support body also has an electrical conductivity of300 S/cm or more, and particularly 440 S/cm or more.

Here, in the fuel cell 3, a portion in which the fuel electrode layerand the oxygen electrode layer face each other via the solid electrolytelayer functions as a power generating element. That is, theoxygen-containing gas, such as air, flows outside the oxygen electrodelayer and the fuel gas (the hydrogen-containing gas) flows in the gasflow passages inside the support body, and the gases are heated to apredetermined actuation temperature, generating power as a result. Then,current generated by this power generation is collected by theabove-described electrically conductive member, via the interconnectordisposed on the support body.

Module

FIG. 11 is an external perspective view illustrating, in an explodedmanner, the module 20 configured by the cell stack illustrated in FIG. 1being contained inside a housing container. The module 20 is configuredby the cell stack device 1 illustrated in FIG. 1 being contained insidea rectangular cuboid-shaped housing container 21.

Here, FIG. 11 illustrates a state in which parts (front and back faces)of the housing container 21 are detached and the cell stack device 1 andthe reformer 6 contained inside have been removed to the rear. In themodule 20 illustrated in FIG. 11, the cell stack device 1 can becontained in the housing container 21 by being slid thereinto.

Furthermore, in the module 20 of the present non-limiting example, sincethe above-described cell stack device 1 is contained in the housingcontainer 21, the module 20 with improved durability can be obtained.

Module Housing Device

FIG. 12 is a perspective view illustrating a non-limiting example of afuel cell device that is the module housing device 40 in which themodule 20 illustrated in FIG. 11 and an auxiliary device configured tooperate the cell stack device 1 are contained inside an external casing.Note that a part of the configuration is omitted in FIG. 12.

In the module housing device 40 illustrated in FIG. 12, the externalcasing configured by supports 41 and exterior plates 42 is divided intoan upper side and a lower side by a dividing plate 43. The upper sideforms a module housing chamber 44 that contains the above-describedmodule 20, and the lower side forms an auxiliary device housing chamber45 that contains the auxiliary device configured to operate the module20. Note that the auxiliary device contained in the auxiliary devicehousing chamber 45 is not illustrated.

Furthermore, an airflow hole 46 is formed in the dividing plate 43. Theair flow hole 46 allows air in the auxiliary device housing chamber 45to flow into the module housing chamber 44. An exhaust hole 47 is formedin a part of the outer plates 42 that configure the module housingchamber 44. Air inside the module housing chamber 44 is dischargedthrough the exhaust hole 47.

In the module housing device 40, as described above, by configuring themodule 20 having improved durability to be contained in the modulehousing chamber 44, it is possible to obtain the module housing device40 having improved durability.

The present disclosure is not limited to the above-describednon-limiting examples, and various modifications can be made withoutdeparting from the scope of the present disclosure. For example, in theabove-described non-limiting examples, the explanation is made usingso-called “vertical cells”. However, horizontal cells referred tocommonly as “horizontal cells”, in which a plurality of power generatingelements are formed on a support substrate, or so-called cylindricalcells may also be used.

Furthermore, the fuel cells 3, the cell stack device 1, the module 20,and the module housing device 40 are described in the above-describednon-limiting examples. However, the present disclosure can also beapplied to electrolytic cells (SOEC) that generate hydrogen and oxygen(O₂) as a result of electrolyzing water vapor (water) by applying watervapor and voltage to a cell, an electrolytic cell stack device and anelectrolytic module that are provided with the electrolytic cells, andan electrolytic device that is a module housing device.

Example 1 Manufacture of Samples

According to the above-described methods for the above-described cellstack device, the manifold and the fuel gas supply pipe were weldedusing the laser welding method, and samples shown in Tables 1 to 4 weremanufactured.

The various members of the cell stack device were the same as thoseillustrated in FIG. 1. Note that, in the present non-limiting example,the cell stack device included the reformer. The thickness of the fuelgas supply pipe was 0.9 mm. Then, the samples having different jointlengths between the first joining portion and the fuel gas supply pipe,or different crystal areas of the crystals in the vicinity of the secondsurface of the first joining portion were manufactured.

Durability Test

Hydrogen-containing gas was caused to flow through the gas flow passagesof the fuel cells of the cell stack device, and further, air was causedto flow on the outer side of the fuel cells (on the outer face of theair electrode layer). Then, power was generated for 24 hours at 850° C.After that, the hydrogen-containing gas was stopped and the cell stackdevice was naturally cooled. The above procedure was repeatedlyperformed up to a predetermined number of repetitions, the test wasstopped, and the presence or absence of cracks was verified. The resultsare shown in Tables 1 to 4.

Note that further testing was not performed on stack devices in whichcracks had occurred at the time of verification.

The test results are shown in Tables 1 to 4. Note that, in Tables 1 to4, the joint length between the first joining portion and the fuel gassupply pipe, an average crystal area value, a maximum crystal areavalue, a value of the average crystal area of the crystals positioned onthe surface of the first joining portion, and a number of cycles of athermal cycling test are listed.

TABLE 1 Average Presence/Absence of Average Maximum crystal cracks afterthermal Joint crystal crystal area value cycling test Sample length areavalue area value at surface 400 420 No. (mm) (μm²) (μm²) (μm²) cyclescycles 1 0.8 9120 30035 1928 Present — 2 0.9 8921 30101 1978 Present — 31.0 9003 28781 1911 Absent Absent 4 1.4 8992 34252 1942 Absent Absent 51.7 9187 30994 1997 Absent Absent 6 1.8 9091 28222 1978 Absent Present 72.2 8934 29716 1954 Absent Present

Durability Test Result 1

For sample No. 1 with the joint length of 0.8 mm and Sample No. 2 withthe joint length of 0.9 mm, cracks occurred in the first joiningportions in the thermal cycling test of 400 cycles. However, for SamplesNo. 3 to 7 with the joint lengths of 1.0 mm or greater, cracks did notoccur in the first joining portions in the thermal cycling test of 400cycles.

For Samples No. 6 and 7 with the joint lengths of 1.8 mm or greater,cracks occurred in the first joining portions in the thermal cyclingtest of 420 cycles. However, for Samples No. 3 to 5 with the jointlengths of 1.0 mm to 1.7 mm, cracks did not occur in the first joiningportions in the thermal cycling test of 420 cycles.

TABLE 2 Average Presence/Absence of Average Maximum crystal cracks afterthermal Joint crystal crystal area value cycling test Sample length areavalue area value at surface 440 460 No. (mm) (μm²) (μm²) (μm²) cyclescycles 1 1.4 13119 30118 1979 Present — 2 1.4 11021 30381 1965 Present —3 1.4 10000 31003 1999 Absent Present 4 1.4 8110 32411 1921 AbsentPresent 5 1.4 6208 29931 1896 Absent Present 6 1.4 4000 28251 1991Absent Absent 7 1.4 3107 30004 1936 Absent Absent

Durability Test Result 2

For Sample No. 1 with the average crystal area value of 13119 μm² andSample No. 2 with the average crystal area value of 11021 μm², cracksoccurred in the first joining portions in the thermal cycling test of440 cycles. However, for Samples No. 3 to 7 with the average crystalarea values of 10000 μm² or less, cracks did not occur in the firstjoining portions in the thermal cycling test of 440 cycles.

For Samples 3 to 5 with the average crystal area values greater than4000 μm², cracks occurred in the first joining portions in the thermalcycling test of 460 cycles. However, for Samples No. 6 and 7 with theaverage crystal area values of 4000 μm² or less, cracks did not occur inthe first joining portions in the thermal cycling test of 460 cycles.

TABLE 3 Average Maximum Average Presence/Absence Joint crystal crystalarea crystal area of cracks after Sample length area value value valueat thermal cycling No. (mm) (μm²) (μm²) surface (μm²) test 480 cycles 11.4 8109 51126 1988 Present 2 1.4 8071 43004 1945 Present 3 1.4 811440000 1989 Absent 4 1.4 8111 32222 1998 Absent 5 1.4 8067 28251 1911Absent

Durability Test Result 3

For Sample No. 1 with the maximum crystal area value of 51126 μm² andSample No. 2 with the maximum crystal area value of 43004 μm², cracksoccurred in the first joining portions in the thermal cycling test of480 cycles. However, for Samples No. 3 to 5 with the maximum crystalarea values of 40000 μm² or less, cracks did not occur in the firstjoining portions in the thermal cycling test of 480 cycles.

TABLE 4 Average Maximum Average Presence/Absence Joint crystal crystalarea crystal area of cracks after Sample length area value value valueat thermal cycling No. (mm) (μm²) (μm²) surface (μm²) test 500 cycles 11.4 8121 32877 2572 Present 2 1.4 8111 33526 2128 Present 3 1.4 800434847 2000 Absent 4 1.4 7974 33442 1765 Absent 5 1.4 8022 35242 1439Absent

Durability Test Result 4

For Sample No. 1 with the average crystal area value at surface of 2572μm² and Sample No. 2 with the average crystal area value at surface of2128 μm², cracks occurred in the first joining portions in the thermalcycling test of 500 cycles. However, for Samples No. 3 to 5 with theaverage crystal area values at surface of 2000 μm² or less, cracks didnot occur in the first joining portions in the thermal cycling test of500 cycles.

REFERENCE SIGNS LIST

-   1 Cell stack device-   3 Fuel cell-   4 Manifold-   5 Cell stack-   6 Reaction gas supply source (reformer)-   9 Reaction gas (fuel gas) supply pipe-   14 Insertion portion-   14 a Gap-   14 b First bent portion-   14 c Second bent portion-   14 d First through hole-   14 e Second through hole-   17 First joining portion-   18 Second joining portion-   D1 Joint length-   D2 Thickness of fuel gas supply pipe-   D3 Thickness of manifold-   D4 Gap length-   20 Module (fuel cell module)-   40 Module housing device (fuel cell device)-   S1 First surface-   S2 Second surface-   S3 First contour line-   S4 Second contour line-   L1 First straight line-   L2 Second straight line

What is claimed is:
 1. A cell stack device comprising: a cell stack comprising a plurality of cells, a manifold configured to supply a reaction gas to the plurality of cells, and a reaction gas supply pipe connected to the manifold, wherein the manifold comprises: an insertion portion configured for connection of the reaction gas supply pipe to the manifold, a gap between the insertion portion and the reaction gas supply pipe, and a first joining portion configured to join the insertion portion and the reaction gas supply pipe and seal one end of the gap on an outer side of the manifold; and in an arbitrarily defined cross-section along an insertion direction of the reaction gas supply pipe, a length of the gap in the insertion direction is longer than a thickness of the manifold.
 2. The cell stack device according to claim 1, wherein a joint length, in the insertion direction, between the first joining portion and the reaction gas supply pipe, is shorter than double a thickness of the reaction gas supply pipe.
 3. The cell stack device according to claim 2, wherein in the arbitrarily defined cross-section along the insertion direction of the reaction gas supply pipe, the joint length in the insertion direction is longer than the thickness of the manifold.
 4. The cell stack device according to claim 1, wherein the reaction gas supply pipe is connected to a reaction gas supply source at one end of the reaction gas supply pipe, the other end of the reaction gas supply pipe is inserted into a first through hole as the insertion portion provided in the manifold and joined to the manifold via the first joining portion, and in the arbitrarily defined cross-section along the insertion direction of the reaction gas supply pipe, an angle θ1 is 30° or less, the angle θ1 being formed between a vertical line drawn from a first leading end portion of the first joining portion to the manifold, and a first straight line connecting the first leading end portion to a first point, the first point being located on a first contour line of the first joining portion and positioned at half a height from a first bottom portion to the first leading end portion of the first joining portion.
 5. The cell stack device according to claim 1, wherein the first joining portion has a concave meniscus shape.
 6. The cell stack device according to claim 1, wherein a first bent portion of the manifold extending away from the manifold along the reaction gas supply pipe is provided around an outer periphery of the insertion portion, and an end portion of the first bent portion and the reaction gas supply pipe are joined via the first joining portion.
 7. A module comprising: the cell stack device according to claim 1 contained in a housing container.
 8. A module housing device comprising: the module according to claim 7; an auxiliary device configured to operate the module; and an external casing configured to contain the module and the auxiliary device therein.
 9. A cell stack device comprising: a cell stack comprising a plurality of cells, a manifold configured to supply a reaction gas to the plurality of cells; and a reaction gas supply pipe connected to the manifold, wherein the manifold comprises: an insertion portion configured for connection of the reaction gas supply pipe to the manifold, a gap between the insertion portion and the reaction gas supply pipe, and a first joining portion configured to seal one end of the gap as a result of joining the insertion portion and the reaction gas supply pipe; in an arbitrarily defined cross-section along an insertion direction of the reaction gas supply pipe, an average crystal area is 10000 μm2 or less with respect to crystals present in an analysis region that is defined by a portion of an outer cross-sectional perimeter of the first joining portion having a length of 500 μm, two parallel lines each having a length of 500 μm and having respective start points at both ends of the portion of the outer cross-sectional perimeter of the first joining portion, and a line joining two end points of the parallel lines opposite the respective start points.
 10. The cell stack device according to claim 9, wherein the average crystal area is 4000 μm2 or less with respect to the crystals present in the analysis region.
 11. The cell stack device according to claim 9, wherein a crystal area of all the crystals present in the analysis region is 40000 μm2 or less.
 12. The cell stack device according to claim 9, wherein in the analysis region, an average crystal area of crystals positioned along the portion of the outer cross-sectional perimeter of the first joining portion is 2000 μm2 or less.
 13. A cell stack device comprising: a cell stack comprising a plurality of cells, a manifold configured to supply a reaction gas to the plurality of cells; and a reaction gas supply pipe connected to a reaction gas supply source at one end of the reaction gas supply pipe and connected to the manifold, wherein the manifold comprises: a main body portion comprising a space communicated with the plurality of cells and a second through hole, a flange portion protruding from the main body portion, the flange portion comprising a first through hole; the first hole is a first insertion portion and the second hole is a second insertion portion, each configured for connection of the reaction gas supply pipe to the manifold; the reaction gas supply pipe is inserted into the first through hole, and the reaction gas supply pipe and the manifold are joined by a first joining portion; and the other end of the reaction gas supply pipe is inserted into the second through hole, and the other end of the reaction gas supply pipe and the manifold are joined via a second joining portion.
 14. The cell stack device according to claim 13, wherein a second gap is between the second insertion portion and the reaction gas supply pipe; the second joining portion is configured to seal one end of the second gap as a result of joining the second insertion portion and the reaction gas supply pipe; and a second joint length, in the insertion direction, between the second joining portion and the reaction gas supply pipe is longer than a thickness of the reaction gas supply pipe.
 15. The cell stack device according to claim 13, wherein in the arbitrarily defined cross-section along the insertion direction of the reaction gas supply pipe, an angle θ2 is 30° or less, the angle θ2 being formed between a vertical line drawn from a second leading end portion of the second joining portion to the manifold, and a second straight line connecting the second leading end portion to a second point, the second point being located on a second contour line of the second joining portion and positioned at half a height from a second bottom portion to the second leading end portion of the second joining portion.
 16. The cell stack device according to claim 13, wherein the first joining portion and the second joining portion have a concave meniscus shape.
 17. The cell stack device according to claim 13, wherein a second bent portion extending away from the manifold along the reaction gas supply pipe is provided by the manifold and around an outer periphery of the second through hole in the manifold, and an end portion of the second bent portion and the reaction gas supply pipe are joined via the second joining portion. 